Double Girder Overhead Crane Exported to Australia: Engineered for Low Headroom Paper Mill

An Australian paper mill required a 5-ton double girder overhead crane for paper roll handling. Due to the limited workshop space and extremely restricted headroom, DGCRANE customized an NLH 5-ton low-headroom double girder overhead crane, successfully meeting the required lifting height within the limited building height.

At the customer’s request, we dispatched engineers to provide on-site installation guidance. The entire process, including installation, commissioning, load testing, and operator training, was completed in just 10 days, helping the customer put the crane into operation smoothly.

Project Overview

The customer is a paper mill in Australia that required a double girder overhead crane for paper roll handling, together with a supporting steel structure. The crane specifications were as follows:

• Lifting capacity: 5t
• Span: 9.42m
• Lifting height: 4.279m
• Working duty: A5
• Voltage: 400V / 50Hz / 3Ph

After reviewing the workshop dimensions, we identified a major challenge: extremely limited building space.

• The workshop was already built with a flat roof and a clear height of only 5.3m, while the required lifting height was not less than 4.279m
• The workshop clear width was 10.7m, and the steel structure width was 10m, requiring special attention to the hook's left-right and front-back limit positions

In addition, the customer had specific electrical requirements:

• Wiring must comply with Australian standards
• Main electrical components and VFDs must be Schneider brand

Based on these working conditions and requirements, we carried out a fully customized design, manufacturing, and delivery solution.

Compact Double Girder Overhead Crane Design: Maximizing Space Utilization

• Hook-up low headroom design
  • The hook can move upward into the cavity between the two main girders, instead of operating only below the beam
  • The hook can rise approximately 94mm above the bottom surface of the main girder
  • Without increasing the overall crane height, an additional ~94mm effective lifting height is gained
• Flat steel runway instead of rail
  • The trolley runway uses 30×50 flat steel laid horizontally
  • This replaces conventional vertical-mounted rails, reducing the vertical space occupied by the runway system
  • Saves tens of millimeters of height space
• Compact overall structure design
  • Optimized main girder cross-section and trolley layout
  • The total crane height (from rail top to equipment top, excluding camber) is only 1159mm
  • Significantly lower than conventional double girder cranes with the same specifications
• Optimized top safety clearance
  • The top safety clearance was finely adjusted while still meeting safety standards
  • Conventional designs typically reserve ≥200mm safety margin; this project optimized it based on actual working conditions
  • Further releases valuable limited headroom

Through the above combined measures, the crane was successfully installed and operated under an extremely limited building height of only 5.3m, achieving a 4.279m lifting height double girder overhead crane operation.

Electrical System: Designed to Australian Grid Standards with Full VFD Control

The electrical system of this project was specially designed according to the requirements of the Australian paper mill, focusing on compliance with Australian industrial wiring standards, adaptation to 400V 50Hz three-phase power, customer-specified brand configuration, and high reliability and safety for paper roll handling applications.

• Wiring standard: Complies with AS/NZS 3000 (Australian Wiring Rules) and relevant Australian industrial electrical standards
• Power supply matching: Australian industrial standard 400V / 50Hz / 3Ph; all main motors, control transformers, contactors, and protection components are selected for 400V rated voltage, enabling direct connection to the workshop power distribution system on site
• Full VFD control: All three mechanisms (hoisting, trolley travel, and crane travel) are equipped with Schneider variable frequency drives. For paper roll handling, VFD control provides practical advantages: smooth low-speed lifting and lowering to avoid damaging paper rolls, and high-speed return during no-load operation to improve efficiency
• Control mode: Wireless remote control + wired pendant control, allowing operators to follow the paper roll on the ground instead of staying at a fixed position. Buttons and remote labels are designed with English text or directional symbols, enabling quick understanding and operation by Australian users

On-site Installation: 10 Days for Installation and Commissioning

According to the customer's requirements, our professional installation engineers were dispatched to Australia for on-site supervision and guidance. From equipment arrival to final acceptance, it took only 10 days to complete installation, commissioning, load testing, and operator training, enabling rapid commissioning of the system.

According to the customer's requirements, our professional installation engineers were dispatched to Australia for on-site supervision and guidance. From equipment arrival to final acceptance, it took only 10 days to complete installation, commissioning, load testing, and operator training, enabling rapid commissioning of the system.

Key issues resolved during installation:

• Missing installation foundations: The site lacked key components such as C-section steel sliding rails, busbars, and anti-derailment brackets. Engineers immediately coordinated material procurement, fabricated installation components on-site, completed welding of busbar supports, and finished installation and power connection once materials arrived
• Limited installation space: Due to low workshop height, installation of walkways, guardrails, and maintenance platforms was restricted. Engineers cut, modified, and re-welded guardrails based on site dimensions and optimized installation methods to ensure safety and usability
• Interference in operating space: Workshop lighting, cameras, and air pipes interfered with trolley movement. After communication with the customer, these facilities were adjusted to eliminate interference and ensure full-range safe operation
• Equipment commissioning and testing: After installation, power-up of busbars, no-load operation, load testing, brake system checks, and VFD parameter tuning were carried out to comprehensively verify performance, ensuring smooth operation, precise positioning, and reliable braking
• Operator training and final acceptance: After commissioning, engineers provided on-site training, explained operation procedures, daily maintenance, and safety precautions in detail, and assisted in load testing and documentation for final acceptance, ensuring independent and safe operation by the customer

Delivery Results

Through structural optimization of the crane system and coordinated on-site installation, the project was successfully implemented and operated stably under extreme space constraints, achieving the following key results:

• Achieved full lifting height functionality of 4.279m under a workshop clear height of only 5.3m
• Systematically optimized main girder, trolley layout, and runway system for low headroom conditions, reducing ineffective vertical space usage
• Completed installation, commissioning, load testing, and operator training of the 5t double girder overhead crane within 10 days, enabling rapid commissioning and reducing waiting time
• Load test passed on the first attempt; hoisting, trolley travel, crane travel, and braking systems all operated normally. The customer reported satisfactory performance and stable operation

Need a Low Headroom Overhead Crane for Tight Workshop?

If your workshop has limited building height, complex clearance constraints, or strict lifting height requirements, a standard overhead crane may not be enough.

DGCRANE specializes in custom low headroom double girder overhead cranes designed for extreme space limitations—without sacrificing lifting height, safety, or reliability.

We provide:

• Tailor-made crane design based on your real workshop drawings
• Low headroom optimization solutions (hook-up design, compact trolley, optimized girder structure)
• Compliance with local electrical standards (AS/NZS, IEC, etc.)
• On-site installation guidance and commissioning support
• Full load testing, operator training, and documentation support

Share your workshop layout or lifting requirements with us, and our engineering team will provide a customized solution within 24 hours.

Contact us today to maximize your lifting height in limited space.

Zora Zhao

Expert in Overhead Crane/Gantry Crane/Jib Crane/Crane Parts Solutions

With 10+ years of experience in the Crane Overseas Export Industry, helped 10,000+ customers with their pre-sales questions and concerns, if you have any related needs, please feel free to contact me!

WhatsApp: +86 189 3735 0200

Email: zorazhao@dgcrane.com